PROPEL HYDRAULIC

ROCK BREAKER G20

Operating, Maintenance and Part Manual

www.propelsystech.com
 Hydraulic Rock Breaker
Operating, Maintenance and Part Manual
UNIT SL NO: ____________________ DISPATCH DATE: ____________________
CUSTOMER: __________________________________________________________
ORDER NO: ____________________________ DATE: ________________________
COMMISSIONING DATE: ______________________________________________

PARTS ORDERING INSTRUCTION

WHILE ORDERING PARTS PLEASE PROVIDE PARTS NO., DESCRIPTION AND

MACHINE SERIAL NO. ETC. SO THAT IT WILL HELP US TO DELIVER THE PARTS
IMMEDIATELY.

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 ROCK BREAKER G20

Hydraulic Rock Breaker-G20

Operating, Maintenance and Part Manual

© 2020. Propel Indenergy Solutions Private Limited Page-iii

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 ROCK BREAKER G20

TABLE OF CONTENTS
1. SPECIFICATION............................................................................................. 1
1.1 GENERAL SPECIFICATION (BOX).................................................................................................2
1.2 TOOL SPECIFICATIONS................................................................................................................. 3

2. OPERATION..................................................................................................5
2.1 PRODUCT NUMBERS.....................................................................................................................6
2.2 SELECTION OF TOOLS.................................................................................................................. 7
2.3 PRINCIPLES OF BREAKING.........................................................................................................7
2.4 CORRECT WORKING METHODS.................................................................................................8
2.5 OPERATING TEMPERATURE........................................................................................................9
2.6 OTHER IMPORTANT POINTS..................................................................................................... 10
2.7 STORAGE...................................................................................................................................... 10
2.8 MOUNTING AND DISMOUNTING THE HAMMER.................................................................... 10
2.9 SETTING OF OPERATING PRESSURE....................................................................................... 11
2.10 SPECIFICATION OF HOSES AND PIPES................................................................................. 12
2.11 HYDRAULIC CIRCUIT.................................................................................................................. 13

3. LUBRICATION............................................................................................. 15
3.1 MANUAL LUBRICATION............................................................................................................... 16
3.2 HYDRAULIC OIL........................................................................................................................... 17

4. MAINTENANCE........................................................................................... 21
4.1 PRECAUTIONS FOR DELIVERY................................................................................................. 23
4.2 INSPECTION OF NITROGEN GAS CHARGING IN THE BACK HEAD.................................... 24
4.3 INSPECTION OF NITROGEN GAS IN THE ACCUMULATOR.................................................. 25
4.4 THE SIDE ROD INSPECTION AND REPLACEMENT............................................................... 27
4.5 ADJUSTING CONTROL METHODS........................................................................................... 28
4.6 REGULATING OIL FLOW RATES OF VALVE ADJUSTER......................................................... 29
4.7 WEAR LIMITS FOR TOOL AND TOOL BUSHING.................................................................... 30
4.8 WEAR LIMIT PART...................................................................................................................... 30
4.9 AUTO SHUT-OFF PLUG..............................................................................................................33
4.10 MAINTENANCE SCHEDULE..................................................................................................... 34

5. DISASSEMBLING AND ASSEMBLING.........................................................35

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 5.1 DISASSEMBLING......................................................................................................................... 36
5.2 ASSEMBLING.............................................................................................................................. 38
5.3 TORQUES..................................................................................................................................... 39
5.4 WORKSHOP TOOL LIST............................................................................................................. 40

6. TROUBLE SHOOTING GUIDE...................................................................... 41

6.1 OIL LEAKAGE................................................................................................................................ 42
6.2 NO IMPACT.................................................................................................................................. 42
6.3 IRREGULAR BLOWS AFTER NORMAL BEGINNING.............................................................. 42
6.4 LACK OF BLOWING.................................................................................................................... 43

7. GENERAL AND SAFETY INFORMATION.................................................... 45

7.1 GENERAL...................................................................................................................................... 46
7.2 SAFETY......................................................................................................................................... 46

8. SPARE PARTS MANUAL............................................................................ 49

8.1 HAMMER (AUTO GREASE)........................................................................................................ 50
8.2 HAMMER (AUTO SHUT OFF).................................................................................................... 55
8.3 HOUSING (OPEN)....................................................................................................................... 60
8.4 HOUSING (BOX)......................................................................................................................... 62
8.5 AUTO GREASE PUMP OPTION................................................................................................. 65

9. TOOL FAILURE ANALYSIS (APPENDIX-I)................................................. 69

9.1 TOOL TROUBLESHOOTING....................................................................................................... 70
9.2 TOOL FAILURE ACCEPTED UNDER WARRANTY.................................................................... 71
9.3 TOOL FAILURE REJECTED UNDER WARRANTY...................................................................... 71

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 ROCK BREAKER G20

1. SPECIFICATION

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 1. SPECIFICATIONS
1.1 GENERAL SPECIFICATION (BOX)

520 700

700
200 200 200
1680

155 150 155

520
Ø27-12 Count

Ø140

445 480

Sr. No Item Specifications

1 Working Weight 1760 kg (3880 lb)
2 Impact Frequency 400 ~ 800BPM
3 Operating Pressure 160 ~ 180 bar
4 Relief Pressure 200 ~ 210 bar
5 Oil Flow 125 ~ 150 l/min
6 Back Pressure 10 bar (145 psi)
7 Tool Diameter 140 mm (5.51 in)

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 ROCK BREAKER G20

Sr. No Item Specifications

8 Oil Temperature -20 ~ +80°C (-4 ~ +176°F)
9 Hydraulic Oil Viscosity 1000 ~ 15 cSt (131 ~ 2.35 °E)
10 Pressure Line Size 25 mm (1 in)
11 Return Line Size 25 mm (1 in)
12 Air (Under Water) PF 1/2”
13 Accumulator Pressure 60 bar (870 psi)
14 Backhead Pressure 8 bar (116 psi)
15 Carrier Weight 18 ~ 25 ton

1.2 TOOL SPECIFICATIONS

Length mm Weight kg Diameter

Name Remark
(in) (lb) mm (in)

Cone Tool (A) 1235 (48.6) 131 (288.6) 140 (5.5)

Cone Tool (B) 1235 (48.6) 134 (295.4) 140 (5.5)

Cone Tool (C) 1200 (47.24) 137 (302) 140 (5.5)

Cone Tool (D) 1235 (48.6) 130 (286.6) 140 (5.5)

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 1.3 STRUCTURE

VALVE BLOCK
BACK HEAD
ACCUMULATOR

PISTON

SIDE ROD

VALVE

CYLINDER

TOOL

FRONT HEAD

1. Side Rod: Front head, cylinder, back head of breaker body are secured with
four side rods.
2. Back head: Gas charging valve are built in and charged with N2 gas to improve
the hammering power.
3. Operating Valve: Control valve is built in the cylinder and controls the piston’s
hammering action.
4. Cylinder: Cylinder is the heart of breaker body.
5. Piston: Kinetic energy of the piston is converted into hammering energy when
the piston hits the tool and consequently breaks rocks
6. Front Head: The front head supports the entire breaker with the thrust ring and
built in upper bushing against the transmitted shock from the tool.
7. Tool: Cone, chisel, blunt, moil can be used in accordance with application.

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 ROCK BREAKER G20

2. OPERATION

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 2. OPERATION
2.1 PRODUCT NUMBERS
The serial number is stamped on the back head and the housing. It is important to
make correct reference to the serial number of the attachment when making repairs or
ordering spare parts.
Identification of the serial number is the only proper means of maintaining and identifying
parts for a specific product.

Serial Number

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 ROCK BREAKER G20

2.2 SELECTION OF TOOLS

PROPEL can offer the selection of standard and special tools to suit each application.
The correct type of tool must be selected to get the best possible working result and the
longest life time for tool.
1. Blunt
• For igneous (e.g. granite) and tough rock metamorphic rock (e.g. gneiss) into
which the tool doesn’t penetrate.
• Concrete
• Breaking boulders.
2. Chisel, cone, moil
• For sedimentary (e.g. sandstone) and weak metamorphic rock into which the
tool penetrates.
• Concrete
• Teaching and benching.

2.3 PRINCIPLES OF BREAKING

There are basically two ways of breaking with a Gas-type breaker.
1. Penetrative (or cutting ) breaking
• In this form of breaking cone point or chisel tool is forced inside the material.
This method is most effective in soft, layered or plastic, low abrasive material.
2. Impact breaking
• In impact breaking, material is broken by transferring very strong mechanical
stress from the tool into material to be broken.
• Best possible energy transfer between tool and object is achieved with a
blunt tool.
• Impact breaking is most effective in hard, brittle and very abrasive materials.

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 2.4 CORRECT WORKING METHODS
1. Prepare the carrier as for normal excavation work.
• Move the carrier to required position.
• Engage the parking brake.
• Set the drive to neutral.
• Disengage the boom lock (if fitted).
2. Set engine speed to the recommended engine RPM.
3. Place tool against the object at 90 degrees.
• Avoid small irregularities on object which will break easily and cause either
idle strokes or incorrect working angle.
• Incorrect working method may cause failure in operation of the breaker or
housing.
4. Use the excavator boom to press the breaker firmly against the object.
• Do not pry the breaker with the boom.
• Do not press too much or too little with the boom.
5. Start the breaker.
6. Do not let tool move outwards from the breaker when it penetrates.
• Feed breaker all the time with excavator boom.
7. Keep the tool at 90 degrees all the time.
• If object moves or its surface breaks, correct the angle immediately.

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• Keep feed forces and tool aligned.

8. Stop breaker quickly.
• Do not allow the breaker to fall down, make idle strokes when the object
breaks. The constant idle stroke has a deteriorating effect on the breaker.
• If breaker falls down, side plates could be worn out more quickly.
9. Do not strike one spot for more than 15 seconds at a time.
• If the object does not break, stop breaker and change the position of the
tool. Otherwise the tool will only make an indentation, which will fill with dust.
This dampens the impact effect and will cause the tool to overheat.
10. When breaking concrete, hard or frozen ground, or any similar material, never
strike and bend with the tool at a same time. This action could cause the tool
to break.

2.5 OPERATING TEMPERATURE

The operating temperature is -20°C ~ 80°C if the temperature is lower than -20°C
(-4°F), the breaker and tool must be preheated before starting the operation in order to
avoid breakage of the accumulator membrane and the tool. During operation they will
remain warm.

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 2.6 OTHER IMPORTANT POINTS
1. Listen to the breaker’s sound while you are using it.
• If the sound becomes thinner and the impact less efficient, the tool is
misaligned with the material and/or there is not enough ‘pressing’ force on
the tool.
• Realign the tool and press the tool firmly against the material.
2. The breaker as a standard assembly, it must not be used under water.
• If water fills the space where the piston strikes the tool, a strong pressure
wave is generated and the breaker may be damaged.

2.7 STORAGE
Long term storage
Observe the following points when the hammer is stored in the way the vital parts of
the attachment are protected from rust and the machine is ready to be used whenever
necessary.
• The storage area must be dry.
• The tool must be removed from the hammer.
• The lower end of the piston, tool and tool bushing must be well protected with grease
in all hydraulic hammers.
• Connections must be sealed with clean plugs to prevent oil leakage and dirt from
getting into couplings.
• The product must be stored in the vertical position.
• Make sure the product cannot fall.

2.8 MOUNTING AND DISMOUNTING THE HAMMER

Removal from carrier
• Position hammers horizontally on the floor and remove the tool.
• Stop carrier engine. Operate boom and hammer controls to release pressure
trapped inside hoses. Wait ten minutes for oil pressure to drop.
• Close hammer inlet and outlet lines. If quick couplers are used, disconnect auto-
matically.
• Disconnect hoses; plug the hoses and the hammer inlet and outlet ports.
• Remove bucket pins and other parts.

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 ROCK BREAKER G20

• The carrier can be moved aside.

Installation
• Install hammer in the same manner as mounting a bucket. Install bucket pins.
• Connect hoses. Hammer inlet port is marked on the back head with “IN” and outlet
port with “OUT”.
• Open hammer inlet and outlet lines.

SPANNER
STOP POSITION

90°

WORKING POSITION

2.9 SETTING OF OPERATING PRESSURE

1. Operating pressure
• Stop the carrier engine.
• Assemble the high pressure gauge to the high pressure measuring port. Start
engine.
• Set tool of the breaker e.g. on a thick steel plate.
• Adjust engine revolution and start operating breaker.
• Read average pressure from high pressure gauge operating pressure.
• Operating pressure is pre-adjusted at the factory and there should be no
reason to adjust it.
• Stop the carrier and remove gauge.
• Tighten plug of the pressure measuring point.

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 2. Relief valve
• The relief valve is a safety device which is used to protect the breaker when
pressure rises in hydraulic circuit.
• The operating pressure of breaker determines the seating of the relief valve
in the pressure line.
• The relief valve setting should be acceptable as per the specifications of
each MSB models.

Pressure Line
Stop Valve Relief Valve
Control Valve
Oil Cooler
Return Filter
Main Pump
Hammer Assembly
Return Line

Operating Pressure
160 - 180 Bar

Relief Pressure
200 - 210 Bar

2.10 SPECIFICATION OF HOSES AND PIPES

Hose Assembly Piping Line Size

Model Remark
In Out In Out
G20 PF 1” PF 1” PF 1” PF 1”

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2.11 HYDRAULIC CIRCUIT

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3. LUBRICATION

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 3. LUBRICATION
3.1 MANUAL LUBRICATION
1. Grease interval
• Tool shank must be well lubricated before installing tool.
• 5-10 stroke from grease gun to tool bushing and tool regular intervals.
• Adapt interval and amount of grease to decrease wearing of tool and good
working conditions.

This should be done every two hours.

Insufficient greasing or improper grease may cause:
• Abnormal wear of tool bushing and tool.
• Tool breakage.

Technical data
• NLGI grade 2
• Synthetic oil base with aluminium complex soap
• Approximately 15% graphite copper solids to reduce metal to metal contact damage
• Dropping point 260°C (500°F)
• Viscosity 15cSt
• Temperature range -30° ~ 230° (-20° ~ 450°F)

GREASING POINT
The greasing point on the hammer has
been marked with the above sticker.

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3.2 HYDRAULIC OIL

• When the breaker is used continuously, the temperature of hydraulic oil
normalise at a certain level depending on conditions of environment and on
the carrier. At this temperature, the viscosity of the hydraulic oil should be
20 ~ 40cSt (2.90 ~ 5.35°E).
• The Propel hydraulic breaker must not be started if the viscosity of the
hydraulic oil is above 1000cSt (131°E) or operated when the viscosity of the
hydraulic oil is below 15cSt (2.35°E).
1. When the oil is too thick, the following problems may occur:
• Difficult start up.
• Stiff operation.
• Breaker strikes irregularly and slowly.
• Danger of cavitations in the pumps and hydraulic breaker.
• Sticky valves.
• Filter bypass, impurities in oil not removed.
2. When the oil is thin, the following problems may occur:
• Efficiency losses (internal leaks).
• Damage to gaskets and seals leaks.
• Accelerated wearing of parts, because of decreased lubrication efficiency.
3. Special Oils
• In some cases special oils (e.g. biological oils and non-inflammable oil)
can be used, please observe following aspects when considering the use of
special oil:
• The viscosity range in the special oil must be in the given range of 15cSt ~
1000cSt (2.35 ~ 131°E)
4. Cleanness of hydraulic oil
• The hydraulic oil filter of the carrier will clean the oil flowing through the
breaker.
• The purpose of the oil filter is to remove impurities from the hydraulic oil
since they cause accelerated component wear, blockages and even seizure.
• Impurities also cause the oil to overheat and deteriorate.
• Air and water are also impurities in oil.

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Page-18
* Recommended Oil, Temperature, Viscosity Viscosity Solidity
40°C point
Name of oil -4 14 32 50 68 85 104 112 140 158 176 °F (104°F) °C(°F)
-20 -10 0 10 20 30 40 50 60 70 80 °C cSt(°E)

Shell Tellus Oil T32 32.0(4.35) -50(-58)

T37 37.0(4.96) -40(-40)
T45 46.0(6.15) -35(-31)

Neste Hydraulic 22 20.5(2.96) -45(-49)

46 44.0(5.85) -39(-38)
68 62.0(8.20) -33(-27)

Esso Unvis N32 31.8(4.32) -45(-49)

N45 45.7(6.20) -39(-38)

Texaca Rardo Oil HDZ32 32.0(4.36) -45(-49)

HDZ45 51.0(6.75) -42(-44)

Tebo Hydraulic Oil 32S 29.0(3.96) -51(-60)

46 46.0(6.15) -51(-60)

Mobil DTE13 29.4(4.01) -45(-49)

DTE15 44.9(5.99) -46(-61)
DTE16 65.9(8.69) -42(-44)

Motor oils

10W 40.0(5.35) -36(-33)

20W/20 51.0(8.06) -36(-15)
SAE30 100(31.2) -31(-24)
6W/20 40.0(5.36) -48(-54)
10W/30 70.0(9.25) -36(-33)
15W/30 100(13.2) -33(-27)

1000cSt(131°E) 40cSt 20cSt 15cSt(236°E)

Permitted Oil temp erature Recommended Oil temp erature

© 2020. Propel Indenergy Solutions Private Limited

 ROCK BREAKER G20

5. Oil Filter
When working with hydraulic breaker, the carrier oil filter must fulfil the
following specifications:
a. The oil filter must be rated at 25 microns maximum.
b. The oil filter must be a standard return line filter rated to maximum working
pressure.
c. The oil filter must have a volume flow capacity of at least twice the breaker’s
maximum flow.
d. The cooler must withstand a dynamic pressure of 290psi (20bar).
e. If the carrier’s oil cooler is too small; either the original cooler must be
replaced with a larger one or an auxiliary cooler must be installed.
6. The auxiliary hydraulic cooler can be installed:
a. In front of the radiator, in which case an additional fan is not required, i.e.
maximum rise of the cooling air is 5°C (40°F).
b. Any other suitable place, using a fan either hydraulically or electrically
driven.
7. Damage caused by hydraulic oil contamination in the carrier and breaker
circuits:
a. The working life of the pumps is significantly shortened.
• Premature wear of parts
• Cavitation Recommended Oil, Temperature, Viscosity
b. Values do not function properly.
• Spools bind
• Blocking of small holes
c. Wear of cylinders and gaskets.
d. Reduced breaker efficiency.
• Premature wear of moving parts and seals
• Danger of piston seizing up
• Oil overheats
e. Shorten working life and reduced efficiency of hydraulic oil.
• Oil overheats
• Oil quality deterioration
• Electrochemical changes in hydraulic oil.

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4. MAINTENANCE

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 4. MAINTENANCE
The hydraulic breaker is a precision product so that good condition by great care and
tidiness should be maintained when handling any components.
Maintenance instructions should be followed to ensure breaker operating in best
condition. Check every components of the machine before and after operating the
breaker and repair or replace the related items if necessary for maximum durability.
1. Clean the machine before inspection
• Breaker housing should be cleaned for removing dirt before inspection to
ensure proper detection of damage of the breaker.
2. Keep away from the heat
• Excavator, breaker body, hydraulic oil still has high level of temperature after
certain operation.
• Due to the reason, do not touch any parts which have high temperature and
wait until they are cooled down, otherwise it may cause serious injury.
3. Release pressure in the hydraulic system
• Before disassembling hydraulic parts (e.g. hydraulic hose, plug, adjust bolt),
make sure that stop valves on both hydraulic lines are fully closed and wait
until the pressure in the hydraulic system of the machine are lowered to
prevent hydraulic oil from popping out.
4. Keep record of inspection history
• Inspect the machine regularly and record the inspection result for future
maintenance.

Periodical Inspection and Schedule

Keep the inspection schedule below thoroughly and conduct an inspection and repair
or replace of the related items for safe use of machine. The times given refer to the
machine hours after the breaker is installed.
1. Every 2 hours Inspection
• Grease the tool shank and the tool bushings (through grease line or grease
nipples).
2. Daily Inspection
• Check the hydraulic hoses/connecting parts for oil leaks and retighten as
needed.
• Check bottom of hammer for any oil leaks and ask dealer for an inspection in
case of oil leakage.

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3. Weekly Inspection
• Check that the side rods are tight and retighten as needed.
• Check that the housing joint bolts and the top cover bolts are tight and
retighten as needed.
• Check that the bushing pins, plugs and snap rings are in place and not
damaged. Replace as needed.
• Check the housing and the top bracket for cracks.
• Check the gas pressure in the back head. Recharge as needed.
4. Monthly Inspection
• Check the tool, the tool pins and the tool bushings for wear. Replace them
when wear exceeds the wear limit.
• Check the damping elements and wear plates for wear. Replace them when
wear exceeds the wear limit.
• Check the main carrier’s hydraulic oil filter. Replace as needed.
5. Every 6 months inspection
• Visual check that every part of the power cell is in good condition.
• Check every bolt and nut for the correct torque.
• Check the gas pressure in the accumulator. Recharge as needed.
• Check that every seal and accumulator membrane. Replace them as needed

4.1 PRECAUTIONS FOR DELIVERY

When PROPEL hydraulic breaker is shipped from the factory, back head is not charged
with N2 gas.
Because if back head is charged with N2 gas, the front head of piston is protruded from
the cylinder.

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 4.2 INSPECTION OF NITROGEN GAS CHARGING IN THE BACK HEAD

1. After installing pressure gauge on charging block, turn handle of charging block
anti-clockwise.
2. Connect gas hose to N2 gas cylinder.
3. Install charging block to charging valve on back head after removing plug from
breaker. (Ensure that O-ring is installed on charging block.)
4. Connect the other end of gas hose to charging block.
5. Turn the handle of N2 gas cylinder anti-clockwise to open and slowly turn handle
of the charging block clockwise to set charging pressure.
6. Turn handle of charging block anti-clockwise, and then turn handle of N2 gas
cylinder clockwise to close.
7. Close cap of charging block after gas hose is relieved from three-way valve.
8. Recheck charging pressure into back head as turning handling of charging block
clockwise.

FULL
OPEN
CLOSE
HANDLE

N2 BACK HEAD

5 bar
SCREW SWITCH CLOSE
N2 GAS CLOSE

GAUGE N2 BACK HEAD

CHARGING
BLOCK
PLUG PUSH
CLOSE
OPEN-CLOSE

CHARGING N2 BACK HEAD

VALVE

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 ROCK BREAKER G20

9. Disconnect gas hose from charging block.

10. Install charging block on charging valve completely.
11. When turn handle of charging block clockwise, gas pressure in back head is
indicated on pressure gauge.
12. If gas pressure is low, perform again operations step 1 through step 8. Repeat
until gas pressure is increased to specified pressure.
13. If gas pressure is excessive, slowly turn adjuster of charging block anti-counter
clockwise. Then gas pressure leaks from the back head. When correct amount
of gas pressure is shown, close adjuster clockwise. When gas pressure is
excessively high, breaker would not operate. Ensure that gas pressure is at
specified pressure and O-ring in charging block is installed.

4.3 INSPECTION OF NITROGEN GAS IN THE ACCUMULATOR

Never use other than N2 gas for charging in Accumulator.

1. Inspection of charging pressure
a. Install pressure gauge on charging block.
b. Turn handle of charging block anti-clockwise.
c. Remove plug on the accumulator and tighten charging block completely.
d. Turn adjuster (2) and turn handle of charging block anti-clockwise slowly
and observe charging pressure on pressure gauge.
e. Ensure charging pressure is correct and tighten adjuster (2) and turn handle
of charging block anti-clockwise completely.
f. Loose screw (1) and install pressure gauge on charging block to discharge
N2 gas from charging block.
g. Remove charging block and tighten plug and cap. (Ensure that O-rings are
installed in plug and cap)
2. Charging N2 gas into the accumulator
a. After performing the same inspection steps of charging pressure, then
remove cap of charging block.
b. Connect gas hose to charging block and N2 gas cylinder.
c. Turn the handle of charging block clockwise.
d. Slowly turn handle of N2 gas cylinder anti-clockwise to charge accumulator
with N2 gas.
e. Tighten adjuster (2) and Connect gas hose to charging block and N2 gas
cylinder completely.

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 f. Turn handle N2 gas cylinder clockwise to close clock.
g. Loose adjuster of charging block to discharge N2 gas remaining in gas hose.
h. Remove gas hose from charging block and N2 gas cylinder.
i. After removing gas hose, adjust the pressure referring step 1 Inspection of
charging pressure.
j. After charging accumulator with N2 gas, check gas leakage from valve, plug
hole of accumulator body.

HANDLE

SCREW(1) SWITCH
N2 GAS

GAUGE
CHARGING
BLOCK
ADAPTER CAP

ADJUSTER(2)

65
bar 60
55
50
45
40
35
30
25

-20 02 04 06 08 0
°C

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4.4 THE SIDE ROD INSPECTION AND REPLACEMENT

Release completely Backhead gas pressure before loosening side rods. Otherwise during
removing of the side rods, a serious accident could be occurred.
• Discharge N2 gas of back head completely before loosening side rods.
• Remove all side rods, and inspect for any cracks and damages on side rods.
• When installing side rods, tighten bolts one turn at a time in diagonal sequence, not
each nut completely all at once.
• Use torque wrench as specified range.

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 4.5 ADJUSTING CONTROL METHODS
• An adjuster which adjusts the number of blows is standard device in our breakers.
• For the most effective breaking, change the number of blows depending on the
working condition:
• Basically by using of adjuster, piston stroke and frequency can be controlled,
meanwhile keeping working pressure and flow rate of oil fixed.
• The adjuster is installed on the right side of cylinder.
• To control the adjuster, rotate the adjusting screw by wrench after taking off nut
from the head of this screw.
• Rotating the screw deep down to the end makes the longest stroke and minimum
number of blows, while rotating the screw upwards by two turn makes the shortest
stroke and gives the number of blows at the maximum.
• After adjustment, tighten up nut to the end.

NUT
ADJUST BOLT

O-RING
BACK UP RING

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4.6 REGULATING OIL FLOW RATES OF VALVE ADJUSTER

Setting Initial status of adjust bolts
1. Loosen the adjust nut to enable the valve adjuster to be turn.
2. Turn the adjust bolt clockwise, and tighten it securely.
3. Turn the adjusting bolt 2.5 turns counter clockwise.
4. After finishing the adjustment, tighten the adjust nut securely.

NUT
ADJUST BOLT
BACK UP RING
O-RING

Number of turns open

2.5 rotation

1. The adjustment of this valve adjuster is needed only when the oil flow and the
operating pressure are less than required specification valve. Otherwise, do
not adjust.
2. The valve adjuster is set at the position of 2.5 times counter clockwise turning
when first released to the customer from factory.
3. DO NOT turn the valve adjuster more than 4 times counter clockwise.

© 2020. Propel Indenergy Solutions Private Limited Page-29

 4.7 WEAR LIMITS FOR TOOL AND TOOL BUSHING
1. The normal clearance between the tool and tool bushing is 6 mm.
In case the tool is contacting the tool bushing or there happens some scratch
on the tools. Please check the wear condition of the tool bushing inside the tool
bushing and change it with new tool bushing.
2. The tool bushing can be used continuously used unless a serious wear is found
on it.

Wear limit

6mm

Surface crack check

4.8 WEAR LIMIT PART

1. Standard inside Diameter of the Part

1. 2. “A”

“B”
“A”

“B”

4. “A” 5. “A”
3.
“B” “B”
“A”

“B”

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 ROCK BREAKER G20

Remark
New(‘A’) Reject(‘B’)
(Unit in mm)
1. Upper Bushing 140 145
2. Tool 140 138
3. Tool Bushing 140 145
4. Stop Pin 20 18
5. Bushing Pin 30 28

2. Tool

Wear
Limit
New Part

NEW REJECT
750mm 400mm

3. Tool Pin
“I”
“H”
“F”

“I”

“G”
“E”

E F G H I
80mm 40mm 77mm 37mm 1.5mm

© 2020. Propel Indenergy Solutions Private Limited Page-31

 4. Wearing Plate

“B”
“A”

NEW(‘A’) REJECT(‘B’)
20mm 18mm

5. Buffer

2.
“A”

“B”

1.

3.
“B”
“A”

“A”
“B”

New(‘A) Reject(‘B’)
1. Side Buffer 85mm 83mm
2. Base Buffer 30mm 28mm
3. Top Buffer 120mm 118mm

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 ROCK BREAKER G20

4.9 AUTO SHUT-OFF PLUG

One of the most potentially damaging events in a breaker’s life is blank firing. The “blank
firing”, that is, when the piston slams down to the bottom of its stroke without contacting
the tool, the energy which should have been transmitted to the workpiece is absorbed in
the breaker body. This can cause so much damage to the inside of a breaker. To lessen
the effect of blank firing, Auto Shut-Off (ASO) system is available.
The operator can selectively adjust On and Off modes of Auto Shut-Off function
according to the given working condition.
The Auto Shut-Off PLUG is on the right side of the cylinder.
In ASO ON mode, the hammer automatically stops when the tool tip is no longer in
contact with the material. It reveals its benefits in a work condition where visibility is
poor (e.g. underwater). This reduces the strain on breaker, and ultimately increases the
hammer lifespan.
In ASO Off mode, the breaker starts without load applied to the tool, thus simplifying
handling by saving time to position the breaker.
This provides great productivity through increased efficiency of hammer operation.
Standard factory setting is ASO On mode which preventing no-load stroke.

ASO PIN
ASO PLUG

ASO PIN
ASO OFF ASO PLUG
ASO PLUG

ASO ON

Adjusting of the modes

1. Switching to ASO Off mode
• Untighten ASO Plug.
• Install ASO PIN (You can find ASO pin in the toolbox).
• Retighten ASO Plug.

© 2020. Propel Indenergy Solutions Private Limited Page-33

 2. Switching to ASO On mode
• Untighten ASO Plug.
• Remove ASO PIN (Keep the ASO PIN well for reuse).
• Retighten ASO Plug.

4.10 MAINTENANCE SCHEDULE

G 2 0 B re a k e r P re v e n ti v e s h e e t
DAY S 45 - 60 1 0 0 -1 20 1 60 - 1 80
HR S 20 0 -3 0 0 5 0 0 - 60 0 80 0 - 90 0
G 20 SCHE D U L E M A IN T A N A N CE SHE E T
NITROGEN GAS CHARGING IN BACKHEAD CHECK / FILL CHECK / FILL CHECK / FILL
NITROGEN GAS CHARGING IN ACCUMULATOR CHECK / FILL CHECK / FILL CHECK / FILL
SIDE ROD INSPECTION & REPLACEMENT INSPECT/TIGHTEN INSPECT/TIGHTEN TIGHTEN/ IF REQUIRED CHANGE.
BLOW ADJUSTER SETTING ADJUST IF REQUIRED ADJUST IF REQUIRED ADJUST IF REQUIRED
GREASING EVERY 1HOUR EVERY 1 HOUR EVERY ONE HOUR
MOUNTING BRACKET FASTNERS CHECK/TIGHTEN CHECK /TIGHTEN CHECK/TIGHTEN
PIPELINE KIT HOSES & FASTNERS CHECK/TIGHTEN CHECK/ TIGHTEN CHECK/TIGHTEN
TOOL BUSH CLEAN WITH DEISEL REPLACE CLEAN WITH DEISEL
UPPER BUSH CLEAN WITH DEISEL REPLACE ROTATION
TOOL PIN ROTATION REPLACE IF NECESSARY ROTATION
SEAL KIT CHECK LEAKAGES REPLACE CHECK LEAKAGES
TOOL - CHISEL / MOIL/ BLUNT CHECK CHECK TOOL PIN AREA & PISTON CHECK/ REPLACE IF NECESSARY
MEMBRANE CHECK REPLACE CHECK
WEARING PLATE CHECK CHECK CHECK/ REPLACE IF NECESSARY
TOP BUFFER CHECK CHECK CHECK/ REPLACE IF NECESSARY
SIDE BUFFER CHECK CHECK/ REPLACE IF NECESSARY CHECK
W/A BLOCK NUT BOLTS CHECK/TIGHTEN CHECK / TIGHTEN CHECK/TIGHTEN
RUBBER & PLUGS CHECK/REPLACE CHECK / REPLACE IF NECESSARY CHECK/REPLACE
CHECKING HYD OIL OF MACHINE INSPECT INSPECT INSPECT / REPLACE IF NECESSARY
RETURN LINE FILTER ELEMENT CLEAN CHECK / REPLACE CLEAN
*** A D V I C E T O R E A D C A R E F U LL
LLYY I N S T R U C T I O N M A N U A L F O R S M OO
OOTTH OP E R A T ION
N o t e . : 1.Chisel must remove from breaker and clean inside the breaker parts like tool pin, tool bush and all pins.
2. Tool pin must rotate every 60-80 Hours
3. N2 Gas must check as per schedule.
4. Check Hydraulic oil before start the breaker.
5. Grease every 1 Hour use only Company recommanded Cheisel Paste.
6. Tighten of Nut Bolts of breaker along with Pipeline Kit (Adaptation Kit)

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 ROCK BREAKER G20

5. DISASSEMBLING AND
ASSEMBLING

© 2020. Propel Indenergy Solutions Private Limited Page-35

 5. DISASSEMBLING AND ASSEMBLING
5.1 DISASSEMBLING

Do not attempt to disassemble or assemble the hammer before reading this chapter of
the manual.

1. Disassembling
a. Put hammer on wooden supports with the equivalent size.
b. Release N2 gas from the back head. Otherwise, it would be very dangerous.
c. Disassemble nuts of side rod from hammer.
d. Disassemble backhead by using of hoist or chain block.

1
4

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 ROCK BREAKER G20

e. Disassemble cylinder with eye bolt and by using chain block or hoist to arrow
direction.

f. Disassemble piston with eye bolt toward upper vertically using chain block
or hoist to arrow direction.
g. Loose and disassemble the side rod from front head in screwing out the
quadrangle part with lower nut by using spanner.

© 2020. Propel Indenergy Solutions Private Limited Page-37

 5.2 ASSEMBLING
1. Seal assembly
Using a brush, lubricating oil should be applied to seal grooves in other to
assemble seals. Much care should be taken when assembling seals.
2. General assembly
a. Assemble side rods to front head with lower nut.
b. Assemble cylinder
c. Lubricate piston thoroughly and slowly and assemble piston and seal
housing. Confirm the direction of seals of cylinder and seal housing.
d. Using a rubber hammer, assemble the seal housing into the cylinder.
e. Assemble back head.
f. Tighten side rod nuts to their specified torque.
g. Assemble removed gas charging valve and pour the hydraulic oil into
cushion chamber.
h. Tighten gas charging valve to its specified torque.
i. Assemble hose adapter.

Page-38 © 2020. Propel Indenergy Solutions Private Limited

 ROCK BREAKER G20

5.3 TORQUES

B A

D
H B

Item N-m Kg.f-m lb.f-ft Remarks Qty

A 2,300 235 1,696 Side Rod Nut 4
B 400 20 495 Accumulator Cover Bolt 12
C 950 96 700 Accumulator Bottom Bolt 4
D 500 50 368 Valve Block Unit 8
E 200 20 150 Valve Block Cover Bolt 4
F 200 20 150 Flange Adaptor Bolt 8
G 650 66 479 Block W.A 4
H 650 66 479 Top Cover Belt 12

© 2020. Propel Indenergy Solutions Private Limited Page-39

 5.4 WORKSHOP TOOL LIST

Qty
No Part Name Spec
O B
1 Top Plate Bolt 36 S/S 2 2
2 In Out Adapter 41 S/S 1 1
3 Side Rod 65 H/S 1 1
4 Cover Bolt 17*19 D/S 1
5 Rubber Plug (-) DRIVER 1
32 S/S 1 1
6 Adjust Bolt
12 L-WRENCH 1 1
32 S/S
7 ASO
12 L-WRENCH
8 Under Water 10 L-WRENCH 1 1
9 Auto Grease Plug 8 L-WRENCH 1 1
10 Tool Pin Eye Bolt M8 1 1
11 Tool Pin Bar 15D 1 1
Gas Charging 27 S/S 1 1
12
(Back Head) 5 T-WRENCH 1 1
13 Tool Pin Snap Ring SNAPRING PLIER 1 1
14 Grease Gun 1 1
15 Acc. Gas Charging 5 L-WRENCH 1 1
16 Housing Joint 75 S/S 1

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 ROCK BREAKER G20

6. TROUBLE SHOOTING
GUIDE

© 2020. Propel Indenergy Solutions Private Limited Page-41

 6. TROUBLE SHOOTING GUIDE
6.1 OIL LEAKAGE

Probable cause Remedy

• Between the tool and tool bushing 1. Replace damaged seals
• Surface of breaker 2. Loose breaker hoses and bolts.
Retighten
• Valve block and bolts
3. Normal: During assembly from
• Between cylinder and back head
lubrication oil and antirust oil applied.
4. Tighten to specified torque.

6.2 NO IMPACT

Probable cause Remedy

• Oil temperature is too low. 1. Oil temperature must reach to min
30°C
• Valve does not operate properly
2. Check breaker operating button in a
• Pressure in backhead and setting
cabin
pressure of relief valve is low.
3. Check pressure of nitrogen gas and
• Poor performance of hydraulic pump
relief valve
4. Contact excavator manufacturer

6.3 IRREGULAR BLOWS AFTER NORMAL BEGINNING

Probable cause Remedy

• Oil temperature increased due to lack 1. Supplement of hydraulic oil
of hydraulic oil.
2. Check gas pressure
• Pressure in back head too high
3. Check pressure of relief valve
• Relief valve is set too low
4. Apply enough down pressure with arm
• Not enough down pressure on tool or boom of carrier

Page-42 © 2020. Propel Indenergy Solutions Private Limited

 ROCK BREAKER G20

Probable cause Remedy

• The clearance between the tool and 5. Check the clearance between tool and
tool bushing is too large tool bushing
• Wear on top of tool 6. Disassemble tool to check
• Poor performance of hydraulic pump 7. Have excavator manufacturer Check
and back pressure is too high piping
• Foreign material inside the valve 8. Disassemble and clean
• Seizure of piston and cylinder 9. Overhaul and check

6.4 LACK OF BLOWING

Probable cause Remedy

• Gas pressure is too low 1. Check gas pressure
• Not enough down pressure on tool 2. Apply enough down pressure with arm
or boom of carrier
• Setting pressure of relief valve is too
low 3. Check pressure of relief valve
• Poor performance of hydraulic pump 4. Check relief valve of excavator
• Operating pressure is too low 5. Check setting pressure

© 2020. Propel Indenergy Solutions Private Limited Page-43

Page-44 © 2020. Propel Indenergy Solutions Private Limited
 ROCK BREAKER G20

7. GENERAL AND SAFETY

INFORMATION

© 2020. Propel Indenergy Solutions Private Limited Page-45

 7. GENERAL AND SAFETY INFORMATION
7.1 GENERAL
Do not use or install the breaker until you can use the carrier. Do not rush the job of
learning. Take your time and learn safely.
• If there is anything you do not understand, ask your PROPEL service centre for
advice.
• The breaker serial number is stamped on a metal plate, which is on the backhead,
nearby the inlet connection.
• Correct reference to the serial number of the breaker is important in case of repairs
or ordering spare parts. Identifying parts for specific breaker is possible only through
serial number.

7.2 SAFETY
1. Manuals
• Read this manual before installing, operating or maintaining the breaker. If
there is anything you don’t understand, ask your employer or your PROPEL
dealer to explain it.
• Keep this manual in good condition.
2. Clothing
• You can be injured if you do not wear proper clothing. Loose clothing can get
caught in the machinery.
• Wear protective clothing to suit the job.
• Example is: a safety helmet, safety shoes, safety glasses, well-fitting overalls,
ear protectors and PROPEL trial gloves. Keep cuff fastened.
3. Work sites
• Inspect the site before working on it.
• Check for potholes, weak ground, hidden rocks etc.
• Check for utilities (electric cables, gas and water pipes etc.)
4. Metal splinters
• You can be injured by flying splinters when driving metal pins in and out.
• Always wear safety glasses.
5. Accumulator

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 ROCK BREAKER G20

• The accumulator is pressurized even when there is no hydraulic pressure in

the breaker.
• Attempting to dismantle the accumulator without first releasing the pressure
can cause serious injury.
• Do not try to dismantle pressure accumulator, contact your PROPEL service
centre first.
6. Hydraulic pressure
• Hydraulic fluid at system pressure is dangerous.
• Before disconnecting or connecting hydraulic hoses, stop the carrier engine
and operate the controls to release pressure trapped in the hoses.
• Keep people away from the hydraulic hoses during breaker operation.

# Regulation and laws #

Observe all laws, work-site and local regulations which affect you and your equipment.
# Practice #
• You and others can be seriously injured if you carry out unfamiliar operation without
practicing them first.
• Practice away from job-site, on a clear area.
• Keep other people away.
• Do not perform new operations until you are sure you can do them safely.

# Equipment condition #
• Defective equipment can injure you or others. Do not operate equipment which is
defective or has missing parts.
• Make sure the maintenance procedures in this manual is completed before using
the equipment.

# Equipment limits #
• Operating the equipment beyond its design limits can cause damage. It can also be
dangerous.
• Do not operate the equipment beyond its limits.
• Do not try to upgrade the equipment’s performance by non-approved modifications.

© 2020. Propel Indenergy Solutions Private Limited Page-47

Page-48 © 2020. Propel Indenergy Solutions Private Limited
 ROCK BREAKER G20

8. SPARE PARTS MANUAL

© 2020. Propel Indenergy Solutions Private Limited Page-49

 8.1 HAMMER (AUTO GREASE)

511
505 509 B
602 604 407 504
404
512 503
510
411 502
511
410 507
506 513
402 501
508
601
403
204

109 215
101 215
C 203
107 A
106 222 221
105 215
201
103 205
102 108 415 209
414
104
202 417 218
414 218
205
416 219
216 B 206
217 210 701 401 C 220
418 208
211
218 207
216 412 406 205
408
413 212
213
A 409 405
214
315
316
301
603
308
314
313
702 305 307
704 307 309
703 705 309
311
311
304
312 306
310

303 302

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 ROCK BREAKER G20

ITEM NO PART NUMBER PART NAME QUANTITY REMARK

101 PRBH11113 BACK HEAD 1
102 PRBH11114 GAS CHARGING V/V ASS'Y 1
103 PRBH11115 FLANGE 2
104 PRBH11116 ADAPTER 2
105 PRBH11117 O-RING 2
106 PRSP11150 SOCKET BOLT 8
107 PRBH11118 O-RING 2
108 PRBH11119 O-RING 1
109 PRBH11120 SOCKET PLUG 1
201 PRCY11112 CYLINDER 1
202 PRCY11113 SEAL HOUSING 1
203 PRCY11114 CONNECTION BUSH 2
204 PRCY11115 PLUG BUSH 1
205 PRCY11116 SOCKET PLUG 4
206 PRSP11151 ADJUST BOLT 2 1
207 PRSP11152 ADJUST NUT 1
208 PRCY11117 HELI-COIL 4
209 PRCY11118 HELI-COIL 8
210 PRCY11119 GAS SEAL 1
211 PRCY11120 STEP SEAL 2
212 PRCY11121 BUFFER RING 1
213 PRCY11122 U-PACKUNG 1
214 PRCY11123 WIPER 1
215 PRBH11117 O-RING 5
216 PRCY11124 O-RING 2
217 PRCY11125 BACKUP RING 3
218 PRCY11126 O-RING 4
219 PRCY11127 O-RING 1

© 2020. Propel Indenergy Solutions Private Limited Page-51

 ITEM NO PART NUMBER PART NAME QUANTITY REMARK
220 PRCY11128 BACKUP RING 1
221 PRCY11129 O-RING 1
222 PRCY11130 GUIDE PIN 1
301 PRFH11112 FRONT HEAD 1
302 PRFH11113 TOOL BUSHING(BOX TYPE) 1 OPTION
TOOL BUSHING(OPEN
303 PRFH11114 1 OPTION
TYPE)
304 PRFH11115 UPPER BUSHING 1
305 PRFH11116 TOOL PIN 2
306 PRFH11117 BUSHING PIN(LOWER) 2
307 PRFH11118 BUSHING PIN(UPPER) 3
308 PRFH11119 SOCKET PLUG 1
309 PRFH11120 RUBBER PLUG 3
310 PRFH11121 RUBBER PLUG 2
311 PRFH11122 SNAP RING 3
312 PRFH11123 SNAP RING 2
313 PRFH11124 GREASE NIPPLE 2
314 PRFH11125 SOCKET PLUG 1
315 PRFH11126 O-RING 1
316 PRCY11130 GUIDE PIN 1
401 PRVB11112 VALVE BLOCK 1
402 PRVB11113 VALVE GUIDE 1
403 PRVB11114 VALVE SPOOL 1
404 PRVB11115 VALVE BLOCK COVER 1
405 PRVB11116 SOCKET PLUG 1
406 PRFH11125 SOCKET PLUG 2
407 PRSP11153 SOCKET BOLT 4
408 PRSP11154 ADJUST BOLT 1 1
409 PRSP11152 ADJUST NUT 1

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 ROCK BREAKER G20

ITEM NO PART NUMBER PART NAME QUANTITY REMARK

410 PRVB11119 O-RING 1
411 PRVB11120 BACKUP RING 1
412 PRCY11129 O-RING 1
413 PRVB11121 BACKUP RING 1
414 PRVB11122 O-RING 2
415 PRVB11123 BACKUP RING 1
416 PRVB11124 O-RING 2
417 PRVB11125 O-RING 2
418 PRVB11126 SOCKET BOLT 8
501 PRAC11112 ACCUMULATOR COVER 1
502 PRAC11113 ACCUMULATOR BOTTOM 1
ACCUMULATOR INNER
503 PRAC11114 1
VALVE
504 PRSP11155 GAS CHARGING BOLT 1
505 PRAC11116 GAS CHARGING CAP 1
506 PRAC11117 MEMBRANE 1
507 PRAC11118 PLUG 1
508 PRSP11156 SOCKET BOLT 12
509 PRAC11120 O-RING 1
510 PRAC11121 BACKUP RING 1
511 PRCY11129 O-RING 2
512 PRAC11122 O-RING 1
513 PRSP11157 SOCKET BOLT 4
601 PRSR11112 SIDE ROD 4
602 PRSP11158 SIDE ROD NUT(UPPER) 4
603 PRSP11159 SIDE ROD NUT(LOWER) 4
604 PRSR11115 SIDE ROD WASHER 4
701 PRSR11116 PISTON 1
702 PRSR11117 TOOL-CONE 1 OPTION

© 2020. Propel Indenergy Solutions Private Limited Page-53

 ITEM NO PART NUMBER PART NAME QUANTITY REMARK
703 PRSR11118 TOOL-CHISEL 1 OPTION
704 PRSR11119 TOOL-BLUNT 1 OPTION
705 PRSR11120 TOOL-MOIL 1 OPTION
PRSR11121 SEAL KIT

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 ROCK BREAKER G20

8.2 HAMMER (AUTO SHUT OFF)

511
505 509 B
602 407 504
604
404
512 503
510
411 502
511
410 507
506 513
402 501
508
601
403 204
215 215
109 203
101 222
C 221
107 A 221
106
105 226
103 227
102 108 415 209
104 414 201
417 205
202 218 218
414 205
416 219
216 B 206
217 210 701 401 C 220
211 418
218 207
216 412 225
208
408 205
413 406 212
213
A 409 405
214
315
316
301
603
308
314
313
702 305 307
704 307 309
703 705 309
311
311
304
312 306
310

303 302

© 2020. Propel Indenergy Solutions Private Limited Page-55

 ITEM NO PART NUMBER PART NAME QUANTITY REMARK
101 PRBH11113 BACK HEAD 1
102 PRBH11114 GAS CHARGING V/V ASS'Y 1
103 PRBH11115 FLANGE 2
104 PRBH11116 ADAPTER 2
105 PRBH11117 O-RING 2
106 PRSP11150 SOCKET BOLT 8
107 PRBH11118 O-RING 2
108 PRBH11119 O-RING 1
109 PRBH11120 SOCKET PLUG 1
201 PRCY11131 CYLINDER 1
202 PRCY11113 SEAL HOUSING 1
203 PRCY11114 CONNECTION BUSH 2
204 PRCY11115 PLUG BUSH 1
205 PRCY11116 SOCKET PLUG 4
206 PRSP11151 ADJUST BOLT 2 1
207 PRSP11152 ADJUST NUT 1
208 PRCY11117 HELI-COIL 4
209 PRCY11118 HELI-COIL 8
210 PRCY11119 GAS SEAL 1
211 PRCY11120 STEP SEAL 2
212 PRCY11121 BUFFER RING 1
213 PRCY11122 U-PACKUNG 1
214 PRCY11123 WIPER 1
215 PRBH11117 O-RING 5
216 PRCY11124 O-RING 2
217 PRCY11125 BACKUP RING 3
218 PRCY11126 O-RING 4
219 PRCY11127 O-RING 1

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 ROCK BREAKER G20

ITEM NO PART NUMBER PART NAME QUANTITY REMARK

220 PRCY11128 BACKUP RING 1
221 PRCY11129 O-RING 1
222 PRCY11130 GUIDE PIN 1
225 PRVB11125 O-RING 1
METRIC HOLLOW HEX
226 PRCY11132 1
PLUG
227 PRCY11133 ASO PIN 1 OPTION
301 PRFH11112 FRONT HEAD 1
302 PRFH11113 TOOL BUSHING(BOX TYPE) 1 OPTION
TOOL BUSHING(OPEN
303 PRFH11114 1 OPTION
TYPE)
304 PRFH11115 UPPER BUSHING 1
305 PRFH11116 TOOL PIN 2
306 PRFH11117 BUSHING PIN(LOWER) 2
307 PRFH11118 BUSHING PIN(UPPER) 3
308 PRFH11119 SOCKET PLUG 1
309 PRFH11120 RUBBER PLUG 3
310 PRFH11121 RUBBER PLUG 2
311 PRFH11122 SNAP RING 3
312 PRFH11123 SNAP RING 2
313 PRFH11124 GREASE NIPPLE 2
314 PRFH11125 SOCKET PLUG 1
315 PRFH11126 O-RING 1
316 PRCY11130 GUIDE PIN 1
401 PRVB11112 VALVE BLOCK 1
402 PRVB11113 VALVE GUIDE 1
403 PRVB11114 VALVE SPOOL 1
404 PRVB11115 VALVE BLOCK COVER 1
405 PRVB11116 SOCKET PLUG 1
406 PRFH11125 SOCKET PLUG 2

© 2020. Propel Indenergy Solutions Private Limited Page-57

 ITEM NO PART NUMBER PART NAME QUANTITY REMARK
407 PRSP11153 SOCKET BOLT 4
408 PRSP11154 ADJUST BOLT 1 1
409 PRSP11152 ADJUST NUT 1
410 PRVB11119 O-RING 1
411 PRVB11120 BACKUP RING 1
412 PRCY11129 O-RING 1
413 PRVB11121 BACKUP RING 1
414 PRVB11122 O-RING 2
415 PRVB11123 BACKUP RING 1
416 PRVB11124 O-RING 2
417 PRVB11125 O-RING 2
418 PRVB11126 SOCKET BOLT 8
501 PRAC11112 ACCUMULATOR COVER 1
502 PRAC11113 ACCUMULATOR BOTTOM 1
ACCUMULATOR INNER
503 PRAC11114 1
VALVE
504 PRSP11155 GAS CHARGING BOLT 1
505 PRAC11116 GAS CHARGING CAP 1
506 PRAC11117 MEMBRANE 1
507 PRAC11118 PLUG 1
508 PRSP11156 SOCKET BOLT 12
509 PRAC11120 O-RING 1
510 PRAC11121 BACKUP RING 1
511 PRCY11129 O-RING 2
512 PRAC11122 O-RING 1
513 PRSP11157 SOCKET BOLT 4
601 PRSR11112 SIDE ROD 4
602 PRSP11158 SIDE ROD NUT(UPPER) 4
603 PRSP11159 SIDE ROD NUT(LOWER) 4

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 ROCK BREAKER G20

ITEM NO PART NUMBER PART NAME QUANTITY REMARK

604 PRSR11115 SIDE ROD WASHER 4
701 PRSR11116 PISTON 1
702 PRSR11117 TOOL-CONE 1 OPTION
703 PRSR11118 TOOL-CHISEL 1 OPTION
704 PRSR11119 TOOL-BLUNT 1 OPTION
705 PRSR11120 TOOL-MOIL 1 OPTION
PRSR11121 SEAL KIT

© 2020. Propel Indenergy Solutions Private Limited Page-59

 8.3 HOUSING (OPEN)

110

103
111
107

109

102 108

107

111
112
113

101

104 105

106

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 ROCK BREAKER G20

ITEM NO PART NUMBER PART NAME QUANTITY REMARK

101 PRHT00005 HOUSING W.A-R/H 1
102 PRHT00006 HOUSING W.A-L/H 1
103 PRHT00007 TOP PLATE 1
104 PRSP11160 JOINT BOLT 8
105 PRSP11161 JOINT NUT 16
106 PRSP11162 JOINT WASHER 16
107 PRHT00008 UPPER SET PLATE 2
108 PRHT00009 LOWER SET PLATE 2
109 PRSP11163 SOCKET BOLT 2
110 PRSP11164 HEX. BOLT 12
111 PRSP11165 PLAIN WASHER 24
112 PRSP11166 SPRING WASHER 12
113 PRSP11167 NYLON LOCK NUT 12

© 2020. Propel Indenergy Solutions Private Limited Page-61

 8.4 HOUSING (BOX)

109

108

110

102
103 A 131
132

107
126
125 118
123

132 134 132

135 133 133
132 134
120

112 114

113
130 122
129
101
117
115 119
128
127 121
104 116

105

106
111

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 ROCK BREAKER G20

ITEM NO PART NUMBER PART NAME QUANTITY REMARK

101 PRHT00010 HOUSIN W.A 1
102 PRHT00016 TOP PLATE 1
103 PRHT00017 WEARING PLATE 1
104 PRHT00018 WEARING PLATE 1
105 PRHT00019 WEARING PLATE 1
106 PRHT00020 WEARING PLATE 2
107 PRHT00021 WEARING PLATE 4
108 PRHT00022 TOP PLATE ASS'Y 1
109 PRHT00023 TOP WEARING PLATE 1
110 PRHT00024 TOP BUFFER 1
111 PRHT00025 BASE BUFFER 1
112 PRHT00026 RUBBER (IN, OUT) 2
113 PRHT00027 RUBBER PLUG 2
114 PRHT00028 RUBBER PLUG 2
115 PRHT00029 RUBBER PLUG 4
116 PRHT00030 RUBBER PLUG 4
117 PRHT00031 RUBBER (GREASE) 2
118 PRHT00032 RUBBER PLUG 2
119 PRHT00033 RUBBER PLUG 4
120 PRHT00034 COVER PLATE-1 1
121 PRHT00035 COVER PLATE-2 1
122 PRHT00036 COVER PLATE-3 1
123 PRHT00037 BLOCK W.A 1
124 PRHT00038 BUFFER BLOCK 1
125 PRHT00039 SHIM PLATE 2
126 PRHT00040 SIDE BUFFER 1
127 PRSP11168 HEX. BOLT 10
128 PRSP11169 SPRING WASHER 10

© 2020. Propel Indenergy Solutions Private Limited Page-63

 ITEM NO PART NUMBER PART NAME QUANTITY REMARK
129 PRSP11170 HEX. BOLT 4
130 PRSP11171 SPRING WASHER 4
131 PRSP11164 HEX. BOLT 12
132 PRSP11165 PLAIN WASHER 32
133 PRSP11166 SPRING WASHER 16
134 PRSP11167 NYLON LOCK NUT 16
135 PRSP11172 SOCKET BOLT 4

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 ROCK BREAKER G20

8.5 AUTO GREASE PUMP OPTION

8.5.1 REFILL UP TYPE

1
9

2
3

4
7
6
5

ITEM NO PART NUMBER PART NAME QUANTITY REMARK

1 PRAG11111 PLATE 1
2 PRAG11112 PUMP 1
3 PRSP11173 SOCKET BOLT 4
4 PRAG11114 COVER 1
5 PRSP11174 SOCKET BOLT 4
6 PRSP11171 SPRING WASHER 4
7 PRSP11176 PLAIN WASHER 4
8 PRAG11118 ADAPTER 1
9 - HOSE 1

© 2020. Propel Indenergy Solutions Private Limited Page-65

 8.5.2 REFILL DOWN TYPE

3
1
9

7
6
5

ITEM NO PART NUMBER PART NAME QUANTITY REMARK

1 PRAG11111 PLATE 1
2 PRAG1122 PUMP 1
3 PRSP11173 SOCKET BOLT 4
4 PRAG11114 COVER 1
5 PRSP11174 SOCKET BOLT 4
6 PRSP11171 SPRING WASHER 4
7 PRSP11176 PLAIN WASHER 4
8 PRAG11118 ADAPTER 1
9 - HOSE 1

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 ROCK BREAKER G20

8.5.3 CATRIDGE UP TYPE

1
9

2
3

4
7
6
5

ITEM NO PART NUMBER PART NAME QUANTITY REMARK

1 PRAG11111 PLATE 1
2 PRAG1121 PUMP 1
3 PRSP11173 SOCKET BOLT 4
4 PRAG1119 COVER 1
5 PRSP11174 SOCKET BOLT 4
6 PRSP11171 SPRING WASHER 4
7 PRSP11176 PLAIN WASHER 4
8 PRAG11118 ADAPTER 1
9 - HOSE 1

© 2020. Propel Indenergy Solutions Private Limited Page-67

 8.5.4 CATRIDGE DOWN TYPE

3
1
9

7
6
5

ITEM NO PART NUMBER PART NAME QUANTITY REMARK

1 PRAG11111 PLATE 1
2 PRAG1123 PUMP 1
3 PRSP11173 SOCKET BOLT 4
4 PRAG1120 COVER 1
5 PRSP11174 SOCKET BOLT 4
6 PRSP11171 SPRING WASHER 4
7 PRSP11176 PLAIN WASHER 4
8 PRAG11118 ADAPTER 1
9 - HOSE 1

Page-68 © 2020. Propel Indenergy Solutions Private Limited

 ROCK BREAKER G20

9. TOOL FAILURE
ANALYSIS (APPENDIX-I)

© 2020. Propel Indenergy Solutions Private Limited Page-69

 9. TOOL FAILURE ANALYSIS (APPENDIX – I)
9.1 TOOL TROUBLESHOOTING

Failure dented by imperfect blow due

NOT WARRANTY
to excessive wear of tool bushing.

Failure due to blank fring or heavy

NOT WARRANTY
wear of tool pin groove.

Failure due to excessive bending,

seizing in tool bushing, prying heavy NOT WARRANTY
objects (Typical failure)

Mushrooming of fast wear of tool tip

caused by blowing on the same spot
NOT WARRANTY
at a time for a long time, levering, and
improper fring.

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 ROCK BREAKER G20

9.2 TOOL FAILURE ACCEPTED UNDER WARRANTY

Material Fault
Fatigue failure is started from the inside of breaker tool. This is the only kind of failure
pattern that is always acceptable for warranty coverage.

Internal Material Flaw

Internal Material Flaw

9.3 TOOL FAILURE REJECTED UNDER WARRANTY

1. Fatigue Failure. (Not Warranty)
This pattern is typical failure caused by prying, levering

X X

Y Y

© 2020. Propel Indenergy Solutions Private Limited Page-71

 a. Fatigue starts from "X" called "Stress Raiser".
b. Size of "Y" area is dependent on how far fatigue has progressed through
section before check all hammer parts and either replace or repair damaged
parts.
2. Excessive Bending (Not Warranty)
Bending stress exceeds material strength causing tools to snap of. It is caused
by wrong working angle or use of tool for mechanical leverage. Failure generally
occurs near front face of tool bushing. Failure type is brittle fracture with a
typical lip formation.

3. Seizing In Tool Bushing (Not Warranty)

Strong side load and striking at the same time can cause damage tool and tool
bushing surface.
This pattern is caused by wrong working angle, wrong or insufcient lubrication
or both.
Failure generally occurs in front tool bushing area.

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 ROCK BREAKER G20

4. Overheating (Not Warranty)

Overheating of tool due to driving the tool end into hard dense material for
too long period of time without penetration will incur fast wear in tool end. The
overheating will soften the tool end causing it to mushroom and peel.

© 2020. Propel Indenergy Solutions Private Limited Page-73

 5. Breaking Or Fast Wear Of Tool Tip (Not Warranty)
This pattern is caused by levering or hammering obliquely (not vertically)

6. Blank Firing (Not Warranty)

Blank fring will incur heavy wear on tool retainer groove. It may cause the
serious wear or damage at tool pin groove area. Therefore, tool pin also could
be often cracked, even broken.

BLANK FIRING IMPACT MARKS FROM

CONTACTING TOOL PIN CONTACTING TOOL PIN

Page-74 © 2020. Propel Indenergy Solutions Private Limited

 ROCK BREAKER G20

NOTES

© 2020. Propel Indenergy Solutions Private Limited Page-75

B-23A, Ecotech-I EXTN, Gautam Budh Nagar
Greater Noida-201308, Delhi NCR

+91 9958882701, +91 8510007406, +91 1141546771

[email protected]

www.propelsystech.com